Veriforce TG CCT 401OP. Training Guide

Transcription

1 Training Guide Directions: This training guide is to be used by a Veriforce Authorized Evaluator/Trainer and Trainee during on-thejob training (OJT) or prior to an evaluation as a resource. (S) Indicates a demonstration or skill task; (K) indicates a knowledge task. OJT Reminder: OJT is an active hands-on process. Practice should be as similar to the actual job task as possible. However, if the training is being provided on an actual job site while a covered task is actually being performed, the Evaluator either needs to be qualified on that covered task or be assisted by someone who is qualified on the covered task. The Evaluator should closely monitor the Trainee's practices to ensure safe and correct task performance. At no time should a non-qualified individual perform, or train for, a covered task unless directed and observed by a qualified individual. However, if the span of control for that particular covered task is 1:0 (requiring only qualified individuals to perform the covered task), the training must be simulated. Training is simulated by "walking through" the task and simulating all actual manipulations (valves, switches, tools, etc.) an individual would use during the performance of a covered task. Simulating includes the use of safety and administrative requirements as if the task were being performed live. Refer to the Veriforce Evaluator Training Program for more on how to conduct formal OJT. Disclaimer: This training resource is offered in good faith. Anyone choosing to utilize or rely on this training resource is doing so at their own discretion, risk and choice. Although every attempt has been made by Veriforce, LLC (the Company ) to ensure the correctness and suitability of this document and to correct any errors brought to the attention of the Company, the Company makes no representation or warranty regarding correctness or suitability (either directly or indirectly) of information referenced or implied within this training resource. In no event shall the Company be liable for any damages (including, but not limited to, special, incidental or consequential damages) whatsoever (including, but not limited to, death, personal injury, damage to person or property, loss of use, and/or loss of revenues), whether in an action of contract, negligence, or other action, arising out of or in any way associated with the use or misuse of this document. All critical information should be independently verified by the user and the user shall not rely on the contents provided herein without such independent verification. The subject matter included in this training has been compiled from a variety of sources and is subject to change without notice. The Company reserves the right to add, remove and alter information contained in this document without notice. The Company may provide links to other sites for your convenience; however, the Company takes no responsibility and makes no representation or warranty regarding the accuracy or currency of information contained within such sites. The Company does not endorse any information, goods, or services referred to within such sites, and the provision of links by the Company shall not be interpreted to be an endorsement of such information, goods or services. The content of this training resource is provided for personal use only, and all other use, copying or reproduction of this training or website or any part of it is prohibited. CCT: 401OP Examination of Buried Pipe When Exposed Page 1 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016

2 Recommended Student Training or Resources: Recommended Student Training or Resources: DOT 49 CFR (a)(1) DOT 49 CFR DOT 49 CFR Examination of Buried Pipe When Exposed Describe a coating inspection on a buried pipeline. Over 98% of pipelines are buried. No matter how well these pipelines are designed, constructed, and protected, once in place, they are subjected to environmental abuse, external damage, coating disbondments, inherent mill defects, soil movements, instability, and third party damage. For this reason, the Department of Transportation (DOT) has adopted regulations ( and ) which require that whenever any portion of a buried pipeline is exposed, the exposed portion must be examined for evidence of external corrosion if the pipe is bare, or if the coating is deteriorated. Examinations should be conducted in the ditch with the pipe - not from the top of the ditch. Too many times major coating problems go undetected from inadequate examinations. Inspection of buried pipelines should include (at a minimum) the following safety precautions: The pipeline has been excavated properly without damage to the pipeline. If anticipated (or expected), only enter after testing the atmosphere of the excavated area for hazardous gases. Proceed when the air is safe or proper personal protective equipment has been provided. Ensure that the trench follows excavation safety procedures (e.g., access and exit ramps, ladders, etc.). Describe the types of defects that might be discovered during a coating inspection. Now that we have discussed how to conduct the inspection process, let s talk about what to look for. Begin by looking for signs of soil discoloration, wetness, or fungus prior to removing the dirt completely away from the pipe. Next, examine the coating thoroughly, and look for coating damage. It is easy to overlook minor damage which can lead to significant corrosion damage later on. Note the overall appearance of the coating, paying close attention to: any bulges, sags, wrinkles, water or mud dripping from the coating, rocks penetrating the coating, melted areas, and discoloration of the coating. Soil Stress Page 2 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016

3 Soil stress is the main cause of pipeline coating failure. This stress is brought about in certain soils that are alternately wet and dry, which creates forces that may split or cause thin areas. Soil stress effects can be seen on coatings as wrinkling, blistering, or cracking. Moisture Under Coating and Blisters Blisters are generally a raised area, often dome shaped (small or large), resulting from loss of adhesion between the coating and the pipe. Very small blisters may be called pinhead blisters or pepper blisters. They may be filled with liquid or air. Blisters are created from moisture working its way through the coating, or from hydrogen gas that forms on the pipeline surface under coating. Disbonded Coatings Coating defects generally take the form of either exposed bare steel, or a disbondment in which the coating remains intact, but a crevice is formed between it and bare steel. Disbonding creates gaps between the coating and pipe surface that fill with ground water, introducing microorganisms that create corrosion cells. A disbonded coating can contain an active corrosion cell that is undetectable until serious damage has occurred to the pipe wall. Look for coatings that are peeling, flaking, separated from the pipeline, or have an asymmetrical look. Peeling, resulting from improper adhesion of the coating, is often related to expansion or contraction of the coating material to the extent it loses its surface adhesion. Generally, peeling is the result of improper surface preparation prior to the application of the coating. Flaking is also a result of improper adhesion of the coating. Flaking occurs because the coating material cures (dries) too quickly or beyond the desired level of flexibility, and in reaching this inflexible state, it shrinks and cracks. These pieces start to curl on the ends, which causes them to pull away from the pipeline. Cracks, Wrinkles, and Sags Cracks are breaks in a coating that extend through to the substrate (or surface of the pipe). Cracking may occur, due to coating formula errors or thick film application. If the coating was applied very thick, and then subsequently the pipe contracted and/or expanded, the coating will crack during curing (or drying time). Wrinkles occur as a result of extreme temperature change, soil stress where the soil shifts, or by applying the coatings too thick. Wrinkles indicate disbonding of coating which could reduce corrosion resistance. Wrinkles may also occur during expansion of the coating, if the coating surface expands more rapidly than the body of the coating during the curing (or drying time). Wrinkling appears as a rough, crinkled surface. Runs and sags are the result of improper coating applications. For example: holding the spray gun too close or too long in one area; or applying coating too thickly and not spreading it out to the proper thickness. Runs and sags may lead to cracks which result in corrosion. Lack of Coating For numerous reasons, pipeline coatings may be removed or knocked loose. Anytime coating damage is discovered, it should be documented and immediately reported to the proper pipeline operator representative. Page 3 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016

4 Describe the types of defects that might be discovered during inspection of the exposed pipe. You ve learned about what to look for during a coating inspection, now let s learn about what to look for during an inspection of exposed pipe. Keep in mind both of these inspections can take place at the same time. There are several defects that you need to pay attention to when conducting an inspection of exposed pipe. Pitting Pitting is a serious form of randomly occurring, highly localized corrosion. Pitting is characterized by small indentations or cavities in the pipe surface. The depth of penetration is much greater than the diameter of the area affected. Pitting is one of the most destructive forms of corrosion, if neglected; even a single pit can cause extensive pipeline damage. Once pits are identified, they must be measured to determine the remaining wall thickness. Document the location and notify the proper pipeline operator representative. Scale Scale is a dense, cohesive material that forms a tightly adhering mass on a metallic surface. Scale is different from mill scale. Mill scale is the black gunk that coats mild steel when you buy it. It is the residue left from the manufacturing process. Examine the pipe for any black mill scale, black dust, or any kind of deposit buildup. Rust, Discoloration, and Corrosion By-Products Carefully look for any unusual colors in the deposits over corroded areas and after removal of the old coating while the surface is fresh. Discoloration indicates the beginning of rusting/corrosion. Wrinkles Pipe wrinkles are also formed when the pipe is bent incorrectly. Wrinkles can lead to accelerated corrosion. Other Physical Damage Physical damage can include buckles, gouges, dents, damaged couplings, defective weld patches, grooves, scratches, or arc burns. If applicable, try to determine the cause of the physical damage (e.g., heavy equipment damaged pipe, improper construction activities). Examine the pipe for anything unusual. Regardless of the size of the physical damage, all damage should be documented, and reported immediately to the proper pipeline operator representative. Describe conditions that may warrant extending the inspection beyond the exposed area. Inspections beyond the exposed area may be necessary if any of the following conditions extend beyond the wall of the excavation: Continuation of an individual pitting area Coating failure Significant general corrosion Page 4 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016

5 Any mechanical defect Exposed metal surface The assumption must be made the damage will extend beyond the excavated area. The DOT requires the pipeline operator to investigate circumferentially and longitudinally beyond the exposed portion (by visual examination, indirect method, or both) to determine whether additional corrosion requiring remedial action exists in the vicinity of the exposed portion. Anytime coating damage, corrosion, or physical damage is discovered on the pipeline, it is important to notify the proper pipeline operator immediately, and document as much as you can about the situation (e.g., location, extent, observations, etc.). Proper identification of the coatings and damage will help facilitate the repair of the area. Abnormal Operating Conditions (s) Candidates are required to possess the ability to RECOGNIZE and REACT to the listed s for each task. Be prepared to answer questions concerning additional s that may be relevant. Evaluators may ask questions about s throughout the evaluation. An is defined in 49 CFR and as: A condition identified by the pipeline operator that may indicate a malfunction of a component or deviation from normal operations that may: Indicate a condition exceeding design limits; or Result in a hazard(s) to persons, property, or the environment. Unintentional releases, vapors, or hazardous atmosphere could be signs that an abnormal operating condition has occurred. Examples could include, but are not limited to: Blowing gas Puddles Dead vegetation Vapors from casing vents Proper reactions/responses to take in the event of an unintentional release, vapors, or hazardous atmosphere include the following: Eliminate potential ignition sources. Move to safe location. Notify emergency response personnel, as appropriate. Limit access to location, as necessary. Follow appropriate procedures for notification, documentation, and remedial action. Material defects, anomalies, or physical damage of pipe or a component that has impaired or Page 5 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016

6 is likely to impair the serviceability of the pipeline are abnormal operating conditions. Examples could include, but are not limited to: Damaged risers Damaged coating Dents Gouges Proper reactions/responses to take in the event of material defects, anomalies, or physical damage of pipe or a component that has impaired or is likely to impair the serviceability of the pipeline include the following: Determine extent, cause, and potential hazard(s) of defect, anomaly, and/or damage. Mark the location so it may be easily located, as appropriate. Follow appropriate procedures for notification, documentation, and remedial action. Failure or malfunction of pipeline component(s) is an abnormal operating condition. Examples could include, but are not limited to: Valve leaking Pipe support failure Mechanical fitting failure Proper reactions/responses to take in the event of a failure or malfunction of pipeline component(s) include the following: Determine extent, cause, and potential hazard(s) of failure and/or malfunction. Protect the public, property, and the environment. Follow appropriate procedures for notification, documentation, and remedial action. Corrosion on a pipeline component that has impaired or is likely to impair the serviceability of the pipeline is considered an abnormal operating condition. Some examples could include, but are not limited to: Evidence of damaged coating or loss of adhesion Notable metal loss Evidence of excess soil stress Proper reactions/responses to take in the event of corrosion on a pipeline component that has impaired or is likely to impair the serviceability of the pipeline include the following: Follow appropriate procedures for notification, documentation, and remedial action. Page 6 of 6 Copyright 2016 Veriforce, LLC. All rights reserved. 09/01/2016